I did a rough concept design of state flags for the United States a couple of years ago using clip art flags and creating a web interface to sell the shirts on. My idea was that as they sold I would print them. Not so. The interface was good, at
MadeForUSA.com and it allowed the potential customer to change the background shirt color, which isn't that hard and I used American Apparel shirts which have a good color range and they are Made in the USA. The problem was most states have colorful designs and as I got a few orders they just sat there getting old as I pondered how to make the design printable with anywhere from 3-6 colors on the average flag. In the end the customers weren't happy and I had a backlog of unfinished work. When I finally spoke with the customer I offered the design as a modified design, less colors, and not exactly what was shown on my website as a design, which usually resulted in a cancelled order. Some of the items got printed after much adoo and a few of the States looked pretty good, although they aren't what was being shown.
The point is that t-shirt printed doesn't easily reproduce artwork exactly as you see it on the web. It's easy to find a picture on a website and/or have an image that you like that was designed for a poster or business card, but they can't magically jump on a t-shirt, even for a t-shirt printer, without a significant amount of work. Also the expected demand for a product is usually less than what was expected and the orders don't just flow to create a demand instantly on the web. There are a few exceptions to the rule and they relate to t-shirt transfers and digitally output image systems that may be direct printed to the shirt. I no longer argue about the quality of those items, but they often wash out and the cost for larger production runs are still high. That said you can get individual shirts made with those types of systems as long as you are willing to pay, I just don't do that type of thing since I am a screen printer or sorts.
The solution is now to rework the designs, as I should have in the first place, and put a little D-stress, eliminate some colors, use the background color of the shirt to match the color of the flag and reduce the overall work required for screenprinting to a 1-2 color job. By modifying and recreating the artwork by reducing the number of colors in each design that will allow me to do small production runs when the time comes. So I am working on one State per day to modify and adjust the designs so that they are printable and represented on the web as I plan to print them. The customer can still change the color of the shirt and we will still use American Apparel, but the shirt will best resemble the respective State flag if it is on the color of the flag for that state. I've shown a few images above of what I started with and what they look like now.
The relevance of this is global for potential custom printing customers. Full color artwork when applied to screen printing t-shirts is usually too complex to simply print it on a shirt. Not to mention expensive and a huge waste of energy to spend hundreds of dollars on screens to make something look exactly like the original. Most artwork can be modified and simplified to work on t-shirts, but it requires that someone familiar with t-shirt printing separate the design into printable colors and in the end it will cost less. Nobody likes to pay for artwork, even me, but unless I spent my time modifying these designs they were unworkable and therefore my business for this State by State Made in the USA t-shirt concept wasn't flying. Now it has a chance and it also has a chance at being profitable since the shirts won't cost as much to make. Most importantly the shirts look better with less colors and they don't have an overwhelming amount of ink on them.
I'm not going to do a new flag design today since this post will count as my day's work on this project. To view the States I've completed go here:
Arkansas State Flag T-shirtNevada State Flag T-shirtArizona State Flag T-shirtWashington State Flag T-shirtOk, I couldn't resist and I had to update this design today for
California.
California State Flag T-shirt
